Sublimated PE Acoustic Panel for Sound Tuning
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Solution Overview
Problem
Existing acoustic treatment solutions, such as printed acoustic panels, require multiple raw materials like fabric and glue, leading to a complex process with high environmental impact and potential compromise of sound absorbing performance due to ink coverage.
Innovation Solution
A sound tuning layer based on polyethylene (PE) or polyethylene terephthalate (PET) is created through sublimation and subsequent cold pressing, maintaining an open cell structure and eliminating the need for fabric and glue, while allowing for dyeing and maintaining acoustic properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If UV printing is used on sound absorbing panels, then printing effectiveness is improved, but sound absorbing performance deteriorates due to ink cover closing the cells
Solution Approach 1:
The patent changes the fundamental parameter of the printing method from UV printing to sublimation printing. This parameter change allows the ink to be applied without closing the cellular structure, thus maintaining sound absorbing performance while achieving effective printing. The sublimation process enables the ink to penetrate and bond with the fabric without forming a surface layer that would block sound waves.
Solution Approach 2:
The patent utilizes the phase transition principle in sublimation printing where the ink transitions directly from solid to gas phase, then re-deposits as a solid on the fabric. This phase transition mechanism allows the ink to be applied without requiring high pressure or heat that would close the cellular structure, thereby preserving acoustic properties while achieving effective printing.
2Measurement precision
If fabric and glue are used in printed acoustic panels, then printing capability is achieved, but process complexity and environmental impact increase
Solution Approach 1:
The patent extracts and eliminates the fabric layer from the traditional acoustic panel structure. By using sublimation printing directly on the foam material, the fabric component is removed entirely, simplifying the manufacturing process and reducing environmental impact while maintaining printing capability.
Solution Approach 2:
The patent merges the printing process with the panel manufacturing process itself. Instead of printing on fabric and then attaching it to foam, the design is directly sublimated onto the foam surface, combining multiple steps into one integrated process that reduces complexity and material usage.
3Measurement precision
If high temperature pressing is used for sublimation, then dyeing is achieved, but corrugated surface and increased roughness occur
Solution Approach 1:
The patent applies preliminary action by performing the sublimation dyeing process first, while the material is still in a softened state, and then immediately followed by cold pressing. This sequence ensures the dye is properly set before the final smoothing operation, achieving both effective dyeing and surface smoothness.
Solution Approach 2:
The patent changes the temperature parameter dynamically during the process: high temperature is applied during sublimation for effective dyeing, then the temperature is reduced for cold pressing to smooth the surface. This parameter change strategy allows the process to achieve both dyeing effectiveness and surface smoothness at different stages.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This innovative solution reduces raw material usage, minimizes environmental impact, and maintains the acoustic performance of the sound tuning layer, providing a simpler and more effective acoustic treatment process.
Implementation Method 1
sublimation of a PE or PET based starting material with an open cell structure, such sublimation comprising pressing a PE based starting material under heat and pressure
Implementation Method 2
subsequent cold pressing, said cold pressing being performed at a lower temperature as regards the sublimation step, and while the sublimated sound tuning layer is still hot
Data Source
AI summary
The present invention is enclosed in the area of acoustic treatment, therefore solutions for adapting/tuning the acoustic performance of a space, wherein such space may take very varied forms: a living space such as a living or sleeping room (100), a lobby or a recording room (100). It is an object of the present invention a sound tuning layer which is PE based and obtained from the steps of sublimation of a PE based starting material with an open cell structure, and subsequent cold pressing, said cold pressing being performed at a lower temperature as regards the sublimation step, and while the sublimated sound tuning layer is still hot, and thereby forming the sound tuning layer, with an open cell structure. It therefore provides a more environmentally friendly and simple solution than those of prior art. It is also an object of the present invention a panel for acoustic treatment of a space, which comprises such layer.